Component for conveying gases

ABSTRACT

This invention provides for a component forming a part of a breathing tube, or forming the breathing tube, for example as a part of a breathing circuit for respiratory therapy. The component comprising a tubular body having a foamed wall. The foamed wall can be formed from extrusion of a single extrudate. The foamed wall is of a sufficient minimum optical transparency such that, in use, there is enabled the visual detection of a liquid (or condensate that may have formed) within the tubular body.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claimis identified in the Application Data Sheet as filed with the presentapplication, are hereby incorporated by reference under 37 CFR 1.57.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to components for medical circuits forconveying gases to and/or from a patient. In one particular aspect, theinvention relates to conduits and in particular to breathing tubes foruse in an inspiratory and/or expiratory limb of a breathing circuit. Inanother particular aspect the invention relates to a tube for a surgicalinsufflation system.

2. Description of the Related Art

In assisted breathing, particularly in medical applications, gaseshaving high levels of relative humidity are supplied and returnedthrough flexible breathing tubes of a relatively restricted sizetypically between a range of approximately 10 mm to 25 mm diameter(covering both neonatal and adult applications). Such breathing tubesare ideally very light, resistant to kinking or pinching but also veryflexible to ensure the greatest performance and level of comfort for thepatient. The light weight of a breathing tube is very important toreduce any forces applied to the patient interface by the weight of thetube. Similarly, breathing tubes must be flexible and able to bendeasily to achieve a high level of patient comfort, which in turn canimprove patient compliance.

In medical applications, such as with assisted breathing, the gasesinhaled by a patient are preferably delivered in a condition havinghumidity near saturation level and at close to body temperature (usuallyat a temperature between 33° C. and 37° C.). Condensation or rain-outcan form on the inside surfaces of the breathing tubes as the highhumidity breathing gases cool and/or come into contact with therelatively cooler breathing tube surface. Breathing gases exhaled by apatient are usually returned fully saturated and flow through anexpiratory breathing tube. If the expired gas is allowed to cool as itpasses along an expiratory breathing tube, condensation or rain-out mayalso occur.

Similarly, Continuous Positive Airway Pressure (CPAP) systems orpositive pressure ventilation systems that provide patients sufferingfrom obstructive sleep apnoea (OSA) with positive pressure breathinggases, also use breathing tubes for delivering (or removing) inspiratory(and/or expiratory) gases.

Condensate forming in a breathing tube (either inspiratory orexpiratory) can be breathed or inhaled by a patient and may lead tocoughing fits or other discomfort. Condensation within a breathing tubemay also interfere with the performance of connected equipment andancillary devices and/or various sensors.

Attempts have been made to reduce the adverse effects of condensation byeither reducing the level of condensation, or providing collectionpoints for draining condensed liquid from the tubing component. Reducingthe condensation or rain-out has generally been achieved by maintainingor elevating the temperature above the dew point temperature of thebreathing gas to reduce the formation of condensation. This temperatureis typically maintained by a heater wire within the breathing tube,although the rain-out performance of these breathing tubes may not becomplete due to a number of factors. Further, previous methods ofheating the gases flow to reduce rain-out, typically result in heatedtubing that has been expensive and/or difficult to manufacture.Particularly, in ‘single use’ applications such as typically found inhospital applications, the manufacturing cost of breathing tubes iscritically important. It is highly desirable to even further reducerainout, while preferably maintaining a low production cost, forexample, by utilising a manufacturing method that is capable of highproduction speeds.

Similarly, during laparoscopic surgery with insufflation, it may also bedesirable for the insufflation gas (commonly CO2) to be humidifiedbefore being passed into the abdominal cavity. This can help prevent‘drying out’ of the patient's internal organs, and can decrease theamount of time needed for recovery from surgery. Even when dryinsufflation gas is employed, the gas can become saturated as it picksup moisture from the patient's body cavity. The moisture in the gasestends to condense out onto the walls of the medical tubing or dischargelimb of the insufflation system. The water vapour can also condense onother components of the insufflation system such as filters. Any vapourcondensing on the filter and run-off along the limbs (inlet or exhaust)from moisture is highly undesirable. For example water which hascondensed on the walls, can saturate the filter and cause it to becomeblocked. This potentially causes an increase in back pressure andhinders the ability of the system to clear smoke. Further, liquid waterin the limbs can run into other connected equipment which isundesirable.

Therefore, it may be advantageous to provide a component or tube capableof having improved thermal insulative characteristics for reducinglikelihood of condensation or rapid build up of liquid within the tubingcomponent.

Further, in attempting to reduce the adverse effects of condensation, itmay be useful for any condensation or other build up of liquid withinthe tubing component to be observable by a patient or their carer; thatis, condensation or other liquid within the component or tube can bevisually or optically detected. In this manner, providing for visual oroptical detection may allow for steps to be taken in managing suchliquid condensation or other liquid that may have built up in the tubecomponent. The ability to visually or optically detect such condensationor other liquid build up within the tube component may also have furtherbenefits in terms of managing the passage of gases to or from a patient,or through a tubing component forming a part of a system for passage ofgases to or from a patient, or for better managing the treatment for thepatient.

In this specification where reference has been made to patentspecifications, other external documents, or other sources ofinformation, this is generally for the purpose of providing a contextfor discussing the features of the invention. Unless specifically statedotherwise, reference to such external documents is not to be construedas an admission that such documents, or such sources of information, inany jurisdiction, are prior art, or form part of the common generalknowledge in the art.

Further aspects and advantages of the present invention will becomeapparent from the ensuing description which is given by way of exampleonly.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a component and/ormethod of manufacturing a component that will at least go some waytowards improving on the above or which will at least provide the publicand the medical profession with a useful choice.

In a first aspect, the present invention may broadly consist in acomponent forming a part of a breathing tube, or forming the breathingtube, comprising: a tubular body having a foamed wall, wherein thefoamed wall is of a sufficient minimum optical transparency such that,in use, enables visual detection of a liquid (or condensate that mayhave formed) within the tubular body.

Preferably the tubular body having the foamed wall is formed fromextrusion of a single extrudate.

In a further aspect, the present invention may broadly consist in acomponent forming a part of a breathing tube, or forming the breathingtube, comprising: a tubular body having a foamed wall formed fromextrusion of a single extrudate, wherein the foamed wall is of asufficient minimum optical transparency such that, in use, enablesvisual detection of a liquid (or condensate that may have formed) withinthe tubular body.

Preferably the wall of the tubular body is corrugated, or of a corrugateprofile, wherein the corrugation profile comprises alternating outercrests (or annular protrusions) and inner troughs (or annular recesses).Preferably the outer crests correspond to a location of maximum innerradius and maximum outer radius of the tubular body, and the innercrests correspond to a location of minimum inner radius and minimumouter radius of the tubular body.

Preferably the corrugations may be of an annular corrugation or a spiralcorrugation form.

Alternatively preferably the tubular body has a substantially uniformwall thickness.

Preferably the tubular body may have a wall thickness of about 0.2 mm toabout 1 mm, or about 0.3 mm to about 0.9 mm, or about 0.4 mm to about0.8 mm, or about 0.5 mm to about 0.7 mm, or about 0.3 mm to about 0.6mm, or about 0.4 mm to about 0.7 mm. The wall may be about 0.2, 0.3,0.4, 0.5, 0.6, 0.7, 0.8, 0.9 or 1 mm thick. Preferably is about 0.4 mmto about 0.8 mm, even more preferably is 0.6 mm thick.

Preferably the foamed wall is thermally insulative of, at least, theinterior of the tubular body bounded by the foamed wall. Preferably, thefoamed wall has a thermal conductivity of about 0.25 to 0.45 W/m-° K(Watts per meter degrees Kelvin). Even more preferably, the foamed wallhas a thermal conductivity of about 0.15 to 0.35 W/m-° K, or about 0.2to 0.4 W/m-° K. Preferably is about 0.3 W/m-° K.

Preferably the foamed wall is a single-piece of a foamed polymermaterial.

Preferably the foamed wall has a void fraction of up to about 10%, or upto about 9%, or up to about 8%, or up to about 7%, or up to about 6% orup to about 5%, or up to about 4%, or up to about 3%, or up to about 2%,or up to about 1%. More preferably, the foamed wall has a void fractionof about 1%, of about 1.5%, of about 2%, of about 2.5%, of about 3%, ofabout 3.5%, of about 4%, or about 4.5%, or about 5%, or about 5.5%, orabout 6%, or about 6.5%, or about 7%, or about 7.5%, or about 8%, orabout 8.5%, or about 9%, or about 9.5%, or about 10%. Most preferably,is about 5.5% or about 7.5%, or is about 5.5% to about 7.5%.

Preferably the extrudate comprises one or more polymer(s) of Linear LowDensity Polyethylene (LLDPE), Low Density Polyethylene (LDPE),Polypropylene (PP), Polyolefin Plastomer (POP), Ethylene Vinyl Acetate(EVA) or blends of these materials. Plasticised PVC may also be asuitable material, but it is not as well accepted for environmentalreasons.

Preferably the extrudate comprises one or more chemical foaming agent.More preferably a chemical foaming agent may comprise calcium oxide.

Preferably the extrudate comprises one or more surface modificationagent. More preferably a surface modification agent may comprise of oneor more of glycerol monostearate (GMS), ethoxylated amine,alkanesulphonate sodium salt, or lauric diethanolamide.

Preferably the polymer comprises at least about 98.4, 98.5, 98.6, 98.7,98.8, 98.9, 99.0, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or99.9 weight percent (wt. %) of the total extrudate. Preferably about98.4 wt. %. More preferably the polymer comprises about 99.49 wt. % ofthe total extrudate. Alternatively preferably the polymer comprisesabout 99.488 wt. % of the total extrudate.

Preferably the chemical foaming agent comprises at least about 0.005,0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013, 0.014, 0.015,0.016, 0.017, 0.018, 0.019, or 0.02 weight percent (wt. %) of the totalextrudate. Preferably about 0.005 wt. %. More preferably the chemicalfoaming agent comprises about 0.01 wt. % of the total extrudate.Alternatively preferably the chemical foaming agent comprises about0.012 wt. % of the total extrudate. Or, comprises about 0.01 wt. % toabout 0.012 wt. %.

Preferably the surface modification agent comprises at least about 0.05,0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 1.1, 1.2, 1.3, 1.4, or1.5 weight percent (wt. %) of the total extrudate. Preferably about 0.05wt. %. More preferably the surface modification agent comprises about0.25 wt. % of the total extrudate. Alternatively preferably the surfacemodification agent comprises about 0.5 wt. % of the total extrudate.Alternatively preferably comprises about 0.25 wt. % to about 0.5 wt. %of the total extrudate.

Preferably the wall of the resultant tubular body enables surfaceproperty contact angles of less than about 50, 45, 40, 35, 30, 25, 20degrees (°), as measurable by an angle measurement device such as ageniometer. Preferably is 45°. More preferably, the wall of theresultant tubular body enables surface property contact angles of about33°.

Preferably the component further comprises a heater. Preferably theheater is associated with a wall of the tubular body. Preferably theheater is associated with an interior wall surface of the tubular body.Preferably the heater is associated with an exterior wall surface of thetubular body. Preferably the heater is embedded, either partially orwholly, in the wall of the tubular body.

Preferably the tubular body further comprises an outer sheath.Preferably the outer sheath surrounds a heater associated with anexterior wall surface of the tubular body. Preferably the outer sheathmay trap air between adjacent outer crests (or annular protrusions) andrestrains a heater, such as a heater wire, associated with an exteriorwall surface of the tubular body.

Preferably the tubular body is a breathing tube and is terminated by afirst connector at an inlet and a second connector at an outlet, andwherein only one gases passageway is provided the length between theinlet connector and the outlet connector.

Preferably the tubular body is a component of a conduit for use in atleast part of an insufflation system. Preferably the tubular body is acomponent of a breathing tube for use in a breathing circuit.

Preferably the tubular body is flexible as defined by passing the testfor increase in flow resistance with bending according to ISO5367:2000(E) (Fourth edition, 2000-06-01).

In a further aspect, the present invention may broadly consist in acomponent forming a part of a breathing tube, or forming the breathingtube, comprising: a tubular body having a foamed wall formed from asingle extrudate, and a heater therein, wherein the foamed wall is of asufficient minimum optical transparency that, in use, enables visualdetection of a liquid (or condensate that may have formed) within thetubular body.

Preferably the wall of the tubular body is corrugated, or of a corrugateprofile, wherein the corrugation profile comprises alternating outercrests (or annular protrusions) and inner troughs (or annular recesses).Preferably the outer crests correspond to a location of maximum innerradius and maximum outer radius of the tubular body, and the innercrests correspond to a location of minimum inner radius and minimumouter radius of the tubular body.

Preferably the corrugations may be of an annular corrugation or a spiralcorrugation form.

Alternatively preferably the tubular body has a substantially uniformwall thickness.

Preferably the tubular body may have a wall thickness of about 0.2 mm toabout 1 mm, or about 0.3 mm to about 0.9 mm, or about 0.4 mm to about0.8 mm, or about 0.5 mm to about 0.7 mm, or about 0.3 mm to about 0.6mm, or about 0.4 mm to about 0.7 mm. The wall may be about 0.2, 0.3,0.4, 0.5, 0.6, 0.7, 0.8, 0.9 or 1 mm thick. Preferably is about 0.4 mmto about 0.8 mm, or is 0.6 mm thick.

Preferably the foamed wall is thermally insulative of, at least, theinterior of the tubular body bounded by the foamed wall. Preferably, thefoamed wall has a thermal conductivity of about 0.25 to 0.45 W/m-° K(Watts per meter degrees Kelvin). Even more preferably, the foamed wallhas a thermal conductivity of about 0.15 to 0.35 W/m-° K, or about 0.2to 0.4 W/m-° K. Preferably is about 0.3 W/m-° K.

Preferably the foamed wall is a single-piece of a foamed polymermaterial.

Preferably the foamed wall has a void fraction of up to about 10%, or upto about 9%, or up to about 8%, or up to about 7%, or up to about 6% orup to about 5%, or up to about 4%, or up to about 3%, or up to about 2%,or up to about 1%. More preferably, the foamed wall has a void fractionof about 1%, of about 1.5%, of about 2%, of about 2.5%, of about 3%, ofabout 3.5%, of about 4%, or about 4.5%, or about 5%, or about 5.5%, orabout 6%, or about 6.5%, or about 7%, or about 7.5%, or about 8%, orabout 8.5%, or about 9%, or about 9.5%, or about 10%. Most preferably,is about 5.5% or about 7.5%, or is about 5.5% to about 7.5%. Preferablyis about 5.5% to about 7.5%.

Preferably the tubular body's foamed wall is foamed by physical foaming,or by chemical foaming, or by a combination of both.

Preferably the extrudate comprises one or more polymer(s) of Linear LowDensity Polyethylene (LLDPE), Low Density Polyethylene (LDPE),Polypropylene (PP), Polyolefin Plastomer (POP), Ethylene Vinyl Acetate(EVA) or blends of these materials. Plasticised PVC may also be asuitable material, but it is not as well accepted for environmentalreasons.

Preferably the extrudate comprises one or more chemical foaming agent.More preferably a chemical foaming agent may comprise calcium oxide.

Preferably the extrudate comprises one or more surface modificationagent. More preferably a surface modification agent may comprise of oneor more of glycerol monostearate (GMS), ethoxylated amine,alkanesulphonate sodium salt, or lauric diethanolamide.

Preferably the polymer comprises at least about 98.4, 98.5, 98.6, 98.7,98.8, 98.9, 99.0, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or99.9 weight percent (wt. %) of the total extrudate. More preferably thepolymer comprises about 99.49 wt. % of the total extrudate.Alternatively preferably the polymer comprises about 99.488 wt. % of thetotal extrudate. Preferably is at least about 98.4 wt. %.

Preferably the chemical foaming agent comprises at least about 0.005,0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013, 0.014, 0.015,0.016, 0.017, 0.018, 0.019, or 0.02 weight percent (wt. %) of the totalextrudate. More preferably the chemical foaming agent comprises about0.01 wt. % of the total extrudate. Alternatively preferably the chemicalfoaming agent comprises about 0.012 wt. % of the total extrudate. Or,comprises about 0.01 wt. % to about 0.012 wt. %. Preferably is at leastabout 0.005 wt. %.

Preferably the surface modification agent comprises at least about 0.05,0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 1.1, 1.2, 1.3, 1.4, or1.5 weight percent (wt. %) of the total extrudate. More preferably thesurface modification agent comprises about 0.25 wt. % of the totalextrudate. Alternatively preferably the surface modification agentcomprises about 0.5 wt. % of the total extrudate. Preferably is about0.25 wt. % to about 0.5 wt. %, or is at least about 0.05 wt. %.

Preferably the wall of the resultant tubular body enables surfaceproperty contact angles of less than about 50, 45, 40, 35, 30, 25, 20degrees (°), by water as measurable by an angle measurement device suchas a geniometer. Preferably is 45°. More preferably contact angles ofabout 20 to about 40 degrees, or about 25 to about 35 degrees, or about28 to about 33 degrees. Even more preferably, the wall of the resultanttubular body enables surface property contact angles of about 33°.

Preferably the heater is associated with a wall of the tubular body.Preferably the heater is associated with an interior wall surface of thetubular body. Preferably the heater is associated with an exterior wallsurface of the tubular body. Preferably the heater is embedded, eitherpartially or wholly, in the wall of the tubular body.

Preferably the tubular body further comprises an outer sheath.Preferably the outer sheath surrounds a heater associated with anexterior wall surface of the tubular body. Preferably the outer sheathouter trap air between adjacent outer crests (or annular protrusions)and restrains a heater, such as a heater wire, associated with anexterior wall surface of the tubular body.

Preferably the tubular body is a breathing tube and is terminated by afirst connector at an inlet and a second connector at an outlet, andwherein only one gases passageway is provided the length between theinlet connector and the outlet connector.

Preferably the tubular body is a component of a conduit for use in atleast part of an insufflation system.

Preferably the tubular body is a component of a breathing tube for usein a breathing circuit.

Preferably the tubular body is flexible as defined by passing the testfor increase in flow resistance with bending according to ISO5367:2000(E) (Fourth edition, 2000-06-01).

In a further aspect, the present invention may broadly consist in acomponent forming a part of a breathing tube, or forming the breathingtube, comprising: a tubular body having a foamed wall formed from asingle extrudate, and wherein the foamed wall is surface modified.

Preferably the foamed wall is surface modified by chemical means orphysical means.

Preferably the foamed wall is surface modified by altering the surfacetension of the wall surface, such as by increasing the surface tensionof the wall surface.

Preferably the foamed wall is of a sufficient minimum opticaltransparency that, in use, enables visual detection of a liquid (orcondensate that may have formed) within the tubular body.

Preferably the wall of the tubular body is corrugated, or of a corrugateprofile, wherein the corrugation profile comprises alternating outercrests (or annular protrusions) and inner troughs (or annular recesses).

Preferably the tubular body is of an annular corrugation or a spiralcorrugation form.

Preferably the outer crests correspond to a location of maximum innerradius and maximum outer radius of the tubular body, and the innercrests correspond to a location of minimum inner radius and minimumouter radius of the tubular body.

Preferably the tubular body has a substantially uniform wall thickness.

Preferably the wall thickness is about 0.2 mm to about 1 mm, or about0.3 mm to about 0.9 mm, or about 0.4 mm to about 0.8 mm, or about 0.5 mmto about 0.7 mm, or about 0.3 mm to about 0.6 mm, or about 0.4 mm toabout 0.7 mm thick.

Preferably the wall thickness is about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7,0.8, 0.9 or 1 mm thick.

Preferably the foamed wall is thermally insulative of, at least, theinterior of the tubular body bounded by the foamed wall.

Preferably the foamed wall has a thermal conductivity of about 0.2 to0.4 W/m-° K (Watts per meter degrees Kelvin), or about 0.15 to 0.35W/m-° K, or about 0.25 to 0.45 W/m-° K.

Preferably the foamed wall has a thermal conductivity resistance ofabout 0.3 W/m-° K.

Preferably the foamed wall is a single-piece of a foamed polymermaterial.

Preferably the foamed wall has a void fraction of up to about 10%, or upto about 9%, or up to about 8%, or up to about 7%, or up to about 6% orup to about 5%, or up to about 4%, or up to about 3%, or up to about 2%,or up to about 1%.

Preferably the foamed wall has a void fraction of about 1% of about1.5%, of about 2%, of about 2.5%, of about 3%, of about 3.5%, of about4%, or about 4.5%, or about 5%, or about 5.5%, or about 6%, or about6.5%, or about 7%, or about 7.5%, or about 8%, or about 8.5%, or about9%, or about 9.5%, or about 10%.

Preferably the foamed wall has a void fraction of about 5.5% to about7.5%.

Preferably the extrudate comprises one or more polymer(s).

Preferably the extrudate comprises one or more of Linear Low DensityPolyethylene (LLDPE), Low Density Polyethylene (LDPE), Polypropylene(PP), Polyolefin, Plastomer (POP), Ethylene Vinyl Acetate (EVA),plasticised Polyvinyl chloride (PVC), or blends of these materials.

Preferably the extrudate further comprises one or more chemical foamingagents.

Preferably the extrudate further comprises one or more chemical foamingagents comprising calcium oxide.

Preferably the extrudate further comprises one or more surfacemodification agents.

Preferably the extrudate further comprises one or more surfacemodification agents comprising glycerol monostearate (GMS), ethoxylatedamine, alkanesulphonate sodium salt, or lauric diethanolamide.

Preferably the extrudate comprises a polymer or polymers being at leastabout 98.4, 98.5, 98.6, 98.7, 98.8, 98.9, 99.0, 99.1, 99.2, 99.3, 99.4,99.5, 99.6, 99.7, 99.8, or 99.9 weight percent (wt. %) of the totalextrudate.

Preferably the extrudate comprises a polymer or polymers being at leastabout 99.49 wt. % or 99.4889 wt. % of the total extrudate.

Preferably the extrudate comprises a chemical foaming agent as at leastabout 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013,0.014, 0.015, 0.016, 0.017, 0.018, 0.019, or 0.02 weight percent (wt. %)of the total extrudate.

Preferably the extrudate comprises a chemical foaming agent as about0.01 wt. % to 0.012 wt. % of the total extrudate.

Preferably the extrudate comprises a surface modification agent as atleast about 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 1.1,1.2, 1.3, 1.4, or 1.5 weight percent (wt. %) of the total extrudate.

Preferably the extrudate comprises a surface modification agent as about0.25 wt. % to 0.5 wt. % of the total extrudate.

Preferably the resultant formed tubular body enables surface propertycontact angles of less than about 50, 45, 40, 35, 30, 25, 20 degrees(°).

Preferably the component further comprises a heater.

Preferably a heater is associated with a wall of the tubular body.

Preferably a heater is associated with an interior wall surface of thetubular body.

Preferably a heater is associated with an exterior wall surface of thetubular body.

Preferably a heater is embedded, either partially or wholly, in the wallof the tubular body.

Preferably the tubular body further comprises an outer sheath.

Preferably the outer sheath surrounds a heater associated with anexterior wall surface of the tubular body.

Preferably the outer sheath outer traps air between adjacent outercrests (or annular protrusions) and restrains a heater, such as a heaterwire, associated with an exterior wall surface of the tubular body.

Preferably the tubular body is a breathing tube and is terminated by afirst connector at an inlet and a second connector at an outlet, andwherein only one gases passageway is provided the length between theinlet connector and the outlet connector.

Preferably the tubular body is a component of a conduit for use in atleast part of an insufflation system.

Preferably the tubular body is a component of a breathing tube for usein a breathing circuit.

Preferably the tubular body is flexible as defined by passing the testfor increase in flow resistance with bending according to ISO5367:2000(E) (Fourth edition, 2000-06-01).

In a further aspect, the present invention may broadly consist in acomponent forming a part of a breathing tube, or forming the breathingtube, comprising:

a tubular body having a foamed wall, the tubular body formed from asingle extrudate. In respect of this aspect, the preferred embodimentsas previously described above may be additionally combined with such atubular body.

In a further aspect, the present invention may broadly consist in acomponent forming a part of a breathing tube, or forming the breathingtube, comprising: a tubular body having a foamed wall, the tubular bodyformed from a single extrudate, the tubular body further comprising ofan outer sheath. In respect of this aspect, the preferred embodiments aspreviously described above may be additionally combined with such atubular body.

In a further aspect, the present invention may broadly consist in acomponent forming a part of a breathing tube, or forming the breathingtube, comprising: a tubular body having a wall with a modified surface,the tubular body formed from a single extrudate. In respect of thisaspect, the preferred embodiments as previously described above may beadditionally combined with such a tubular body.

In a further aspect, the present invention may broadly consist in acomponent forming a part of a breathing tube, or forming the breathingtube, comprising: a tubular body having a wall with a modified surface,the tubular body formed from a single extrudate, the tubular bodyfurther comprising of an outer sheath. In respect of this aspect, thepreferred embodiments as previously described above may be additionallycombined with such a tubular body.

In a further aspect, the present invention may broadly consist in amethod of forming a component forming a part of a breathing tube, orforming the breathing tube, comprising: extruding a tubular body from asingle extrudate, the extrudate including a foaming agent for foaming ofthe tubular body so formed, such that, the wall of the foamed tubularbody is of a sufficient minimum optical transparency that is use enablesvisual detection of a liquid (or condensate that may have formed) withinthe tubular body.

Preferably the method further comprises passing the extruded tubularbody into a corrugator and forming corrugations in the extruded tubularbody having a corrugation profile comprising alternating outer crests(or annular protrusions) and inner troughs (or annular recesses).

Preferably the corrugations may be of an annular corrugation or a spiralcorrugation form.

Preferably the method further comprises terminating a first end with afirst connector, and terminating a second end with a second connector,and wherein only one gases passageway is formed between the firstconnector and the second connector.

Preferably the method further comprises applying one or more of a heateror a sheath about the tubular body.

Preferably the heater is associated with a wall of the tubular body.Preferably the heater can be either associated with an interior wallsurface of the tubular body or an exterior wall surface of the tubularbody. Alternatively preferably, such a heater can be embedded, eitherpartially or wholly, in the wall of the tubular body.

Preferably the component further comprises a heater. Preferably theheater is associated with a wall of the tubular body. Preferably theheater is associated with an interior wall surface of the tubular body.Preferably the heater is associated with an exterior wall surface of thetubular body. Preferably the heater is embedded, either partially orwholly, in the wall of the tubular body.

Preferably the tubular body further comprises an outer sheath.Preferably the outer sheath surrounds a heater associated with anexterior wall surface of the tubular body. Preferably the outer sheathmay trap air between adjacent outer crests (or annular protrusions) andrestrains a heater, such as a heater wire, associated with an exteriorwall surface of the tubular body.

In a further aspect the invention consists in a component forming a partof a breathing tube, or forming the breathing tube, comprising: atubular body having a foamed wall having a foamed wall formed fromextrusion of a single extrudate, wherein the tubular body furthercomprises an outer sheath.

In a further aspect the invention consists in a component forming a partof a breathing tube, or forming the breathing tube, comprising: atubular body having a foamed wall, and wherein the foamed wall issurface modified and the tubular body further comprises an outer sheath.

In a further aspect the invention consists in components as hereindescribed with reference to any one or more of the drawings.

The term “comprising” as used in this specification and claims means“consisting at least in part of”. When interpreting each statement inthis specification and claims that includes the term “comprising”,features other than that or those prefaced by the term may also bepresent. Related terms such as “comprise” and “comprises” are to beinterpreted in the same manner.

This invention may also be said broadly to consist in the parts,elements and features referred to or indicated in the specification ofthe application and/or statements of invention, individually orcollectively, and any or all combinations of any two or more said parts,elements features or statements of invention, and where specificintegers are mentioned herein which have known equivalents in the art towhich this invention relates, such known equivalents are deemed to beincorporated herein as if individually set forth.

The invention consists in the foregoing and also envisages constructionsof which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way ofexample only and with reference to the drawings, in which:

FIG. 1 illustrates a section of a corrugated tubular component,including a partial cut-away side view of a medical tube componentaccording to one embodiment of the invention, for example a breathingtube or a limb of an insufflation system, optionally including thesheath shown on a part of the tube component.

FIGS. 2A and 2B are section views through a wall section of a tubegenerally illustrating different void fractions generated by foaming;FIG. 2A generally illustrating a lower void fraction (lower than that ofFIG. 2B) of a foamed tubular body wall having greater transparency orclarity (or greater ease of visual detection of liquid within a tube);FIG. 2B generally illustrating a greater void fraction (greater thanthat of FIG. 2A) of a foamed tubular body wall having reducedtransparency or clarity (or reduced ease of visual detection of liquidwithin a tube).

FIG. 3 is a schematic illustration of one type of breathing circuit inwhich a component according to the invention can be used.

FIG. 4 is a schematic illustration of a patient and a humidifiedinsufflation system showing the inlet and exhaust limbs.

FIG. 5 is a schematic illustration of one preferred forming method formedical tubing.

FIG. 6 is a schematic illustration of a further preferred forming methodfor medical tubing, including hopper feed, screw feeder to a die head,and terminating with a corrugator.

FIG. 7 is a generalised view of a foamed tubular body according to oneembodiment of the invention incorporating a heater wire within thepassageway of the tubular body.

FIG. 8 is a generalised view of a foamed tubular body according to oneembodiment of the invention incorporating a heater wire located aboutthe external surface of the tubular body's outer wall surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the field of medical circuits, and in particular breathing circuits(including anaesthetic circuits), condensation or rain-out can be aparticular problem where high humidity breathing gases come into contactwith the walls of a component at a relatively lower temperature.Enhancing the thermal resistance (or thermal insulation capabilities) ofthe walls provides benefits in this respect. However, it remainsbeneficial for a user or care-giver to be able to optically identify orvisually discern the presence of liquid or build-up of condensate withinthe component. The present invention is directed toward enabling acomponent providing a patient and care-giver with both of thesebeneficial requirements.

With reference to FIG. 3 a humidified ventilation system is shown inwhich a patient 100 is receiving humidified and pressurised gasesthrough a patient interface 102 connected to a humidified gasestransportation pathway or inspiratory breathing tube 103. It should beunderstood that delivery systems could also be continuous, variable orbi-level positive airway pressure or numerous other forms of respiratorytherapy. The inspiratory tube 103 is connected to the outlet 104 of ahumidification chamber 105 which contains a volume of water 106. Theinspiratory tube 103 may contain a heater or heater wires (not shown)which heat the walls of the tube to reduce condensation of humidifiedgases within the tube. The humidification chamber 105 is preferablyformed from a plastics material and may have a highly heat conductivebase (for example an aluminium base) which is in direct contact with aheater plate 107 of humidifier 108. The humidifier 108 is provided withcontrol means or electronic controller which may comprise amicroprocessor based controller executing computer software commandsstored in associated memory.

In response to the user set humidity or temperature value input via dial110, for example, and other inputs, the controller determines when (orto what level) to energise heater plate 107 to heat the water 106 withinhumidification chamber 105. As the volume of water within humidificationchamber 105 is heated, water vapour begins to fill the volume of thechamber above the water's surface and is passed out of thehumidification chamber outlet 104 with the flow of gases (for exampleair) provided from a gases supply means or ventilator/blower 115 whichenters the chamber 105 through inlet 116. Exhaled gases from thepatient's mouth are returned to the ventilator via a return expiratorybreathing tube 130.

The ventilator 115 is provided with variable pressure regulating meansor variable speed fan 121 which draws air or other gases through blowerinlet 117. The speed of variable speed fan 121 is controlled byelectronic controller 118. It will be appreciated that the patientinterface 102 could equally be a nasal mask, oral mask, oronasal mask,nasal prongs or full-face mask, etc.

However, there are also other competing requirements that should besatisfied by medical tubing in the field of the present invention. Forexample, it is preferable that breathing tubes for breathing circuitsare: resistant to crushing; resistant to restrictions in flow when bent(increased resistance to flow <50% when bent around a 1 inch cylinder);resistant to kinking; resistant to changes in length/volume underinternal pressure (compliance); resistant to leaking (<25 ml/min @ 6kPa); have low flow resistance (increase in pressure @ max. rated flow<0.2 kPa); electrically safe i.e.: sparks in the tubing can be extremelydangerous, especially in oxygen-rich environments such as oxygentherapy.

International standard ISO 5367:2000(E) (Fourth edition, 2000-06-01) isone example of how some of these desirable parameters are measured andassessed, and the document is hereby incorporated into thisspecification in its entirety by reference. It is preferable thatcomponents of the invention meet or exceed some or all of thesestandards.

In this specification, terms “medical circuit” and “breathing circuit”are used to indicate the general field of the invention. It is to beunderstood that a “circuit” is intended to include open circuits, whichdo not form a complete closed circuit. For example, CPAP systems usuallyconsist of a single inspiratory breathing tube between a blower and apatient interface. The term “breathing circuit” is intended to includesuch “open circuits”. Similarly, the term “medical circuit” is intendedto include both breathing circuits and insufflation circuits (which arealso typically “open”). Similarly, the term “medical tubing” is intendedto be read as flexible tubing suitable for use in the type of medicalcircuits described above connecting between components of a medicalcircuit and providing a gases pathway between components of a medicalcircuit.

The term “substantially uniform” wall thickness corrugated tube isintended to mean a tube having a corrugation profile wherein an outerpeak, for example, comprises the maximum outside radius of the tubewhile also forming the maximum inner radius of the tube and an innertrough, for example, forms the minimum inner and outer radius of thetube. This type of tube is typically formed from a substantially uniformthickness extrusion that is subsequently corrugated. It will beappreciated that the subsequently formed corrugations may vary the wallthickness of the outer peak regions versus the inner trough regions ofthe finished tube. The ratio of minimum to maximum actual wall thicknessmay vary as much as 1:1.5-3.0 for example.

It will be generally understood that a “single extrudate” as used inthis specification and claims means a single batch, or blend, orformulation, or mixture of material (or materials), that is fed to anextruder to be extruded. In this manner, a single layer extrusion isformed. It will be appreciated that this is in contrast to a multi-layerextrudate, such as for example those formed by co-extrusion orextrusion-coating techniques.

The phrase “visual detection” as used in this specification and claimsis intended to mean recognition by human eye, for example, a person isable to visually recognise the presence, or build-up of a liquid (orcondensate that may have formed) within at least a part of the tubularbody. A further example includes where people are capable of visuallyrecognising the presence or build-up of a liquid (or condensate that mayhave formed) in a tubular body according to this invention, whensubjected to the “visual detection test method” as described herein.

Breathing Tubing

Medical tubing in the field of the present invention has a nominal boresize from approximately 10 mm to approximately 30 mm, and lengthsranging from approximately 300 mm to 2.5 m. In particular applicationssuch as medical tubing to connect to an interface component the tubingmay be significantly shorter (e.g. 50 mm to 300 mm) A catheter mount forexample, may have a length of approximately 80 mm. A catheter mount is asingle lumen tube which in use will carry both inspiratory andexpiratory breathing gases to and from a patient respectively.

Foamed Embodiment

In a first embodiment there is provided a component 1 forming a part ofa breathing tube (such as for example inspiratory tube 103), or formingthe breathing tube. The component 1 comprises of a tubular body 2 havinga foamed wall 3 formed from extrusion of a single extrudate. The foamedwall 3 is of a sufficient minimum optical transparency such that, inuse, enables visual detection of a liquid (or condensate that may haveformed) within the tubular body 2.

In another embodiment however, there is provided a component 1 forming apart of a breathing tube (such as for example inspiratory tube 103), orforming the breathing tube. The component 1 comprises of a tubular body2 having a foamed wall 3 formed from extrusion of a single extrudate.Alternatively in another embodiment, there is provided a component 1forming a part of a breathing tube (such as for example inspiratory tube103), or forming the breathing tube. The component 1 comprises of atubular body 2 having a foamed wall 3, the tubular body 2 formed from asingle extrudate, where the tubular body further comprises of an outersheath 7. In both these embodiments, additional features andcombinations with such embodiments are contemplated in the form of, forexample, optional heating elements, external sheaths, techniques forsurface modification of the tubular body's wall, including ways andamount of foaming of the wall 3, and whether the conduit is of acorrugated form or not.

In yet further embodiments however, there is provided a component 1forming a part of a breathing tube (such as for example inspiratory tube103), or forming the breathing tube. The component 1 can comprise of atubular body 2 having a wall 3 with a modified surface, the tubular bodyformed from a single extrudate. Alternatively, in another embodiment,there is provided a component 1 forming a part of a breathing tube (suchas for example inspiratory tube 103), or forming the breathing tube. Thecomponent 1 can comprises of a tubular body 2 having a wall 3 with amodified surface, the tubular body 2 formed from a single extrudate,where the tubular body further comprising of an outer sheath 7. Again,and as stated previously, in both these embodiments additional featuresand combinations with such embodiments are contemplated in the form of,for example, optional heating elements, external sheaths, techniques forsurface modification of the tubular body's wall, including ways andamount of foaming of the wall 3, and whether the conduit is of acorrugated form or not.

FIGS. 2A and 2B generally illustrate foamed tubular body wall sectionalviews. FIG. 2A illustrates a wall section having a void fraction lessthan the void fraction of the wall in FIG. 2B. The void fraction helpingto improve insulator capabilities of the component 1. Voids are shown asgas bubbles or foamed voids 18.

FIG. 2A generally illustrates a wall having an optical claritysufficient to enable visual detection of a liquid or condensate that mayhave built-up within the tubular body 2 of such a component 1. Suchoptical characteristic allows a user or care-giver to visually discernthe presence of liquid within the tubular body, and if necessary, takeaction to drain the liquid from the component, or taker other necessaryaction. Or, at least allow maintenance to be undertaken.

In contrast, although not specific to the illustration of FIG. 2B, FIG.2B generally illustrates that the greater the level of void fraction,the greater the likelihood of opacity or reduced optical clarity ortransparency through the wall of the tubular body 2. The void fractionof the wall should be at least of a level that allows a minimum oftransparency for optical detection by a user or care-giver of a patientusing such a tubular body (or component 1).

The wall 3 of such a tubular body 2 can be optionally corrugated, or ofa corrugate profile (for example as shown in FIG. 1). For example, thecorrugation profile can comprise of alternating outer crests 4 (orannular protrusions) and inner troughs 5 (or annular recesses). Theouter crests 4 can correspond to a location of maximum inner radius andmaximum outer radius of the tubular body, and the inner troughs 5 cancorrespond to a location of minimum inner radius and minimum outerradius of the tubular body. Such corrugations may be of an annularcorrugation or spiral corrugation form. Alternatively, the tubular bodymay be of a smooth or non-corrugate profile.

The tubular body 2 advantageously has a substantially uniform wallthickness. A wall thickness of about 0.2 mm to about 1 mm, or about 0.3mm to about 0.9 mm, or about 0.4 mm to about 0.8 mm, or about 0.5 mm toabout 0.7 mm, or about 0.3 mm to about 0.6 mm, or about 0.4 mm to about0.7 mm. The wall may be about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9 or1 mm thick.

Such a foamed wall 3 preferably provides a level of thermal insulativeof, at least, the interior (or gas flow passage) of the tubular body 2bounded by the foamed wall 3. In particular, the wall 3 is thermallyinsulative of the contents (such as for example humidified gases flowingthrough the gas flow passage) of the tubular body 2 to the potentialcooling effects of the environment surrounding the tubular body (forexample, insulating from the ambient air surrounding a breathingcircuit, or a laparoscopic insufflation system). The environmentsurrounding the component or tubular body 2 is for example, a hospitalward or room, an operating theatre, or other locations where the patientmay be located.

The foamed wall 3 is a single-piece of a foamed polymer material, forexample being formed by extrusion of a single extrudate.

Foaming of the tubular body's wall 3 allows enhanced thermal insulativeproperties of the component as part of a breathing tube or breathingcircuit, for example. More specifically, the foamed wall 3 may providefor overall increased thermal insulative properties of the component,particularly of, at least, the interior of the tubular body bounded bythe foamed wall. In various embodiments the foamed wall 3 has orprovides for a thermal conductivity of about 0.2 to about 0.4 W/m-° K(Watt per meter Kelvin). It will however be appreciated the foamed wall3 may beneficially provide for other levels of thermal conductivity,advantageously thermal conductivities of about 0.15 to 0.35 W/m-° K orof about 0.25 to 0.45 W/m-° K are preferred.

As part of foaming the wall of the tubular body 2, the foaming providesfor certain gas voids 18 within the wall 3. A quantitative measure ofthe gas voids 18 can be expressed as a void fraction. A void fraction isindicative of the volume of void (gas) space occupying a unit volume ofthe tubular body.

The gas voids 18 may assist in contributing to the insulationperformance of the component 1, in addition to enabling the desiredlevel of tubular wall transparency.

A minimum level of transparency of the tubular wall 2 enables the visualdetection of liquid (or condensate that may have built-up within thetubular body or component) by a person.

Various levels of void fraction can be of up to about 10%, or up toabout 9%, or up to about 8%, or up to about 7%, or up to about 6% or upto about 5%, or up to about 4%, or up to about 3%, or up to about 2%, orup to about 1%, or ranges of void fractions of the tubular body's wallof about 1%, of about 1.5%, of about 2%, of about 2.5%, of about 3%, ofabout 3.5%, of about 4%, or about 4.5%, or about 5%, or about 5.5%, orabout 6%, or about 6.5%, or about 7%, or about 7.5%, or about 8%, orabout 8.5%, or about 9%, or about 9.5%, or about 10%.

According to the applicant's test results, the most preferred voidfractions to be formed in a tubular body's wall is about 5.5% or about7.5%, or is about 5.5% to about 7.5%. Such void fractions enable aperson to optically identify or visually discern the presence of liquid,accumulated liquid or other build-up of condensate (for example as aresult of rain-out).

The tubular body's foamed wall 3 can be foamed either by physicalfoaming techniques, or by chemical foaming techniques, or by acombination of both of these.

The extrudate may comprise of a number of polymer materials to whichother materials may be added (for example by blending as or to form amaster batch). Preferred materials include one or more polymer(s) ofLinear Low Density Polyethylene (LLDPE), Low Density Polyethylene(LDPE), Polypropylene (PP), Polyolefin Plastomer (POP), Ethylene VinylAcetate (EVA) or blends of these materials.

Plasticised PVC may also be a suitable material, but it is not as wellaccepted for environmental reasons.

The polymer material can comprises at least about 98.4, 98.5, 98.6,98.7, 98.8, 98.9, 99.0, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8,or 99.9 weight percent (wt. %) of the total extrudate. In particularembodiments the polymer material comprises about 99.49 wt. % of thetotal extrudate (as LLDPE).

Alternatively preferably the polymer comprises about 99.488 wt. % of thetotal extrudate.

Surface Modification

One such additional material that can be included with the extrudate isone or more surface modification agents.

A surface modification agent may preferably comprise glycerolmonostearate (GMS), ethoxylated amine, alkanesulphonate sodium salt, orlauric diethanolamide.

Preferably the surface modification agent comprises at least about 0.05,0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 1.1, 1.2, 1.3, 1.4, or1.5 weight percent (wt. %) of the total extrudate. More preferably thesurface modification agent comprises about 0.25 wt. % of the totalextrudate. Alternatively preferably the surface modification agentcomprises about 0.5 wt. % of the total extrudate.

For example, MLDNA-418 supplied by Clariant (New Zealand) Ltd. and underthe product name “418 LD Masterbatch Antistatic” is a surfacemodification agent master batch with 5(±0.25) % glycerol monostearate(CAS No. 123-94-4) as an active ingredient.

A surface modification agent may additionally be included in theextrudate. Such an agent assists in increasing the surface energy (orthe wettability) of the surface of the formed component or tube. In thismanner, advantageously increasing the surface energy may act to promotereduced contact angles between drops or beads of condensate or liquidthat may build up on the surface.

The contact angle is the angle formed by the solid surface of thecomponent or tube wall and the tangent line to the upper surface at theend point of a liquid droplet. Contact angle measurement is anon-destructive method of determining the wetting behaviour of liquidson a solid surface. It enables the calculation of surface andinterfacial tension along with spreading coefficients. The surfacetension calculated from the contact angle data are a characteristicmeasurement for the respective surface and fluid system.

The contact angle between a liquid and a surface is measured using agoniometer (angle measurement device). A precise volume of the liquid isdispensed on the cleaned and dried flat test surface using a precisionsyringe. The droplet is allowed to stabilize for a few seconds and ahigh magnification camera is used to capture the image of the droplet.The image is digitised and the angle between the test surface and thetangent line along the droplet surface is measured.

Reducing contact angle increases contact area between the droplet andsolid surface, and also reduces droplet thickness, enhancing heatconduction through the droplet. Both effects increase dropletevaporation rate.

Increasing the energy of a surface reduces contact angle of a dropletplaced on the surface. In this manner, a droplet of liquid on thesurface of a higher energy surface can preferentially have a greatersurface area in contact with the surface, then a surface of relativelylower energy.

Advantageously, the droplet may be spread across a larger surface areaof the surface and, therefore, be more likely to re-evaporate into thegas stream flowing through the component or tube.

For example, the droplet or bead may spread across the internal surfaceof the tube's wall, allowing greater surface area for re-evaporationinto the passing gas stream.

In another example, where the tube is corrugated (whether as an annularcorrugate or spiral corrugate form), the droplet or bead of water ismore likely to form in a part of the corrugation of low temperatureposition (i.e. generally this is a part of the corrugation closest to ormost exposed to ambient conditions surrounding the tube). In such acase, altering the surface properties of the tube surface can promote adroplet or bead formed at the low temperature position to spread acrossthe tube surface and in doing so may move towards a region of warmertemperature. Such migration of movement of the droplet or bead can allowfor further improved re-evaporation rates, both due to the dropletpossibly moving toward regions of warmer temperatures, as well aspossibly toward regions of the tube which are exposed to greater orfaster gas stream flows. Greater re-evaporation rates may therefore beachieved by providing for improved migration of a droplet or beadradially inward from the internal surface wall of the tube.

In respect of surface modification, it should be appreciated that invarious aspects of the invention, a component 1 and its tubular body 2can be formed from a single extrudate where the body 2 has a modifiedsurface. Modified surfaces may preferably facilitate the advantages ofre-evaporation rates or droplet migration as described above.

Some of the other methods which may be used to increase surface energyinclude:

Physical

-   -   Physical adsorption    -   Langmuir-Blodgett film

Chemical

-   -   Oxidation by strong acids    -   Ozone treatment    -   Chemisorption    -   Flame treatment

Radiation

-   -   Plasma (glow discharge)    -   Corona discharge    -   Photo-activation (UV)    -   Laser    -   Ion beam    -   Electron beam

γ-irradiation

A chemical additive or agent can also be used to impart the increase insurface energy and wettability to the component or tube so formed.

Such a surface modification agent may for example be glycerolmonostearate, a food grade emulsifier.

TABLE 1 Contact angle measurements for samples of LLDPE with differentsurface treatments Average Contact Description of Surface Liquid Angle(degrees) Linear Low-density Polyethylene (LLDPE), Water 97.39 asmanufactured Linear Low-density Polyethylene (LLDPE), Water 67.56fluorinated, washed Linear Low-density Polyethylene (LLDPE), Water 44.98plasma-treated, 10% O2, 300 Watts, 30 seconds Linear Low-densityPolyethylene (LLDPE), Water 33.09 with 5% MLDNA-418 as surfacemodification agent additive

The sample with 5% MLDNA-418 surface modification agent produced thelowest measured contact angle compared to other surface modificationmethods tested.

In Table 1 above and where referenced elsewhere in this specification,contact angle measurements were based on static drop shape testingmethods conducted in accordance with ASTM Standard D7334, 2008,“Standard Practice for Surface Wettability of Coatings, Substrates andPigments by Advancing Contact Angle Measurement”.

Modifying the surface properties of the tubular body 2 (i.e. the foamedwall 3 of the resultant tubular body) enables variation of the surfaceproperty contact angles.

By choosing various surface modification methods, it is possible toprovide a foamed wall 3 having surface property contact angles of lessthan about 50, 45, 40, 35, 30, 25, 20 degrees (°), as measurable by anangle measurement device such as a geniometer. Advantageously, foamedwalls 3 of a resultant tubular body enabling surface property contactangles of less than about 35° appear to provide useful results.

Foaming

Another additional material to be included with the extrudate is one ormore chemical foaming agents.

A chemical foaming agent enables foaming of the extrudate material aspart or after the extrusion process.

For example, the chemical foaming agent can comprise at least about0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013, 0.014,0.015, 0.016, 0.017, 0.018, 0.019, or 0.02 weight percent (wt. %) of thetotal extrudate.

In preferred embodiments, the chemical foaming agent can comprise about0.01 wt. % to about 0.012 wt. % of the total extrudate.

As part of a chemical foaming extrusion process, the polymer resincomponent of an extrudate is mixed with a chemical foaming agent.Chemical foaming agents are sometimes also referred to as blowingagents.

Some preferred chemical foaming agents include those that comprisecalcium oxide. For example, MHYNA-CF20E supplied by Clariant (NewZealand) Ltd. under the product name Hydrocerol CF20E is a chemicalfoaming agent in the form of a blowing agent master batch with about0.5-1% calcium oxide as an active ingredient.

During a chemical foam extrusion process the polymer resin component andchemical foaming agent(s) are mixed and melted. The chemical foamingagent(s) decomposes and liberates gas which is dispersed in the polymer(or master batch or extrudate) melt and which expands upon exiting thedie of an extruder.

It will also be appreciated other foaming techniques can be employed forthe forming of a foamed wall 3 of the component 1 or tube, such as byphysical rather than chemical foaming methods. Physical foaming methodswould include gas being introduced directly into the melt or extrudatewhile under pressure. As the melt or extrudate is then extruded thepressure is reduced allowing the gas to expand. For example, one suchphysical foaming technique includes blowing or injecting of gas(es) intoextrudate at or near the point of extrusion. Such gas(es) may includenitrogen, carbon dioxide, pentane or butane.

Heaters and Sheaths

The component 1 can optionally further include a heater 6 (as shown forexample in FIGS. 4, 7, 8).

The heater can be associated with a wall of the tubular body, forexample an interior wall surface (such as FIGS. 4, 7) or an exteriorwall surface (such as FIG. 8) of the tubular body.

In other embodiments, the heater can be embedded, either partially orwholly, in the wall 3 of the tubular body 2 (not shown).

In yet a further embodiment, the tubular body 2 can optionally includean outer sheath 7. Such an outer sheath 7 surrounds the tubular body 2.

Where a heater is associated with an exterior surface of the tubularbody 2, the sheath 7 would additionally surround or envelope the heater.

However, it is also contemplated that in various aspects of theinvention an outer sheath 7 may surround the component 1, whether aheater is included with the tubular body 2 or not.

The sheath 7 is contemplated as being provided in various forms. Forexample, the sheath 7 may be applied about the tubular body 2 as anextruded outer layer, as a wrapping about the body 2, or as a sleevethat is slid or pulled into position about the tubular body 2. Such asheath 7 may be formed of similar materials as the tubular body 2, forexample LLDPE (low low density polyethylene). The sheath 7 may assist infurther improving thermal performance of the tubular body 2. The sheath7 may be of any necessary thickness, although thickness and the materialused should be balanced with the need to maintain flexibility of thetubular body 2.

In one embodiment it is contemplated an outer sheath 7 may have a wallthickness of about 100 micrometres.

Where an outer sheath 7 is extruded about the tubular body 2, forexample, such an extrusion could be a sequential step to initialextrusion of the tubular body 2, that is, an extrusion steppost-formation of the body 2. Further, where an outer sheath 7, forexample, is a wrap about the body 2, the sheath 7 may be of a tape orribbon form and can be spirally wound about the length of the body 2.Still further, where an outer sheath 7 is pre-formed as a hollow tube,it may be sleeved into position about the outside of the body 2.

Where a heater 6 is employed however, the heater 6 can be of a heaterwire form. Materials for such heater wires are copper, aluminium or aPTC (positive temperature coefficient) type material. Aluminium is notas conductive as copper, but may be an economical choice even though thewire diameter is larger for the same resistance. While the appliedcircuit voltage is intrinsically safe (less than 50V), for corrosionresistance and best electrical safety in the event of the tube or sheathbeing damaged, the wire will ideally be self insulated, either by enamelcoating or anodising in the case of aluminium. Alternatively an extrudedplastic sheath can be fitted about the heater wire.

Further advantageously, the outer sheath 7 may trap air between adjacentouter crests 4 (or annular protrusions). This may assist in furtherinsulation of the gas passing through passage of the component 1. Wherefor example a heater 6 is employed with the component 1 and an outersheath is also used, the outer sheath 7 can help to restrain the heater6, such as a heater wire, in position when the heater is associated withan exterior wall surface of the tubular body.

Where the component 1 is a breathing tube, or a part of a breathingtube, it can be terminated by a first connector 8 at an inlet 9 and asecond connector 10 at an outlet 11 (for example as shown in FIG. 3). Inthis manner, only one gases passageway is provided the length betweenthe inlet connector and the outlet connector.

In other contemplated forms, the component 1 with its tubular body 2 canform a part or further component of a conduit for use in at least partof an insufflation system (for example such as that shown in FIG. 4). Inaddition, the component 1 with its tubular body 2 can alternatively forma part of or a further component of a breathing tube for use in abreathing circuit (for example such as that shown in FIG. 3).

Foamed Heater Embodiment

In another embodiment there is provided a component 1 forming a part ofa breathing tube, or forming the breathing tube (such as for example asillustrated in FIG. 3 or 4). Such a component 1 comprises of a tubularbody 2 having a foamed wall 3 formed from a single extrudate, andincluding a heater 6 therein.

The foamed wall 3 is of a sufficient minimum optical transparency that,in use, enables visual detection of a liquid (or condensate that mayhave formed) within the tubular body 2.

The details for such a further embodiment are similar to that previouslydescribed in the first embodiment above.

Reference can also be made to FIGS. 7 and 8 generally illustrating atubular body including a heater 6, such as a heater wire.

FIG. 7 illustrates the placement of a heater wire within the internalpassageway of the tubular body, while FIG. 8 illustrates the placementof a heater wire about the external surface of the tubular body's wall.

More particularly, with this embodiment the heater 6 is associated witha foamed wall 3 of the tubular body 2.

It will be appreciated there are various forms in which the heater 6 canbe associated with a wall of the tubular body as previously discussed.

In a further option, the tubular body 2 may optionally be surrounded byan outer sheath 7, the operation and benefits of which are previouslydiscussed. The outer sheath 7 may be employed, whether or not a heater 6is also included.

In both the embodiments described above, such a method of forming acomponent 1 forming a part of a breathing tube, or forming the breathingtube, comprises extruding a tubular body from a single extrudate. Thesingle extrudate including a foaming agent for foaming of the tubularbody so formed, such that, the wall 3 of the foamed tubular body 2 is ofa sufficient minimum optical transparency that is use enables visualdetection of a liquid (or condensate that may have formed) within thetubular body 2.

In one such embodiment, the method comprises passing the formed extrudedtubular body 2 into a corrugator and forming corrugations along theextruded tubular body having a corrugation profile comprisingalternating outer crests 4 (or annular protrusions) and inner troughs 5(or annular recesses). The corrugator may form annular or spiralcorrugations.

In one embodiment of the invention, the component forming a part of abreathing tube, or forming a breathing tube, is formed according to thesteps of i) mixing or providing of a master batch of extrudate material(i.e. material for extrusion), ii) feeding the master batch to anextrusion die head, iii) extruding the extrudate into a tubular body forthe component. Optionally, the tubular body is further fed into acorrugator for forming of corrugations.

Such a master batch can be provided with a chemical foaming agentincluded, and optionally a chemical surface modification agent may beincluded (although it will be appreciated other forms of surfacemodification agent techniques may be used, for example the physicaltechniques as described herein).

In one example, the process used to make such a component involvesextruding a molten tubular profile into a corrugator machine utilisingan endless chain of mould blocks to form a flexible corrugated tube.

An extruder such as a Welex extruder equipped with a 30-40 mm diameterscrew and typically a 12-16 mm annular die head with gap of 0.5-1.0 mmhas been found to be suitable for producing low cost tubes quickly.Similar extrusion machines are provided by American Kuhne (Germany),AXON AB Plastics Machinery (Sweden), AMUT (Italy), Battenfeld (Germanyand China).

A corrugator such as those manufactured and supplied by Unicor®(Hassfurt, Germany) has been found to be suitable for the corrugationstep. Similar machines are provided by OLMAS (Carate Brianza, Italy),Qingdao HUASU Machinery Fabricate Co., Ltd (Qingdao Jiaozhou City, P.R.China), or Top Industry (Chengdu) Co., Ltd. (Chengdu, P.R. of China).

FIG. 6 generally illustrates a further setup where there is provided afeed hopper 12 for receiving raw ingredients or material (e.g. masterbatch and other materials) to be passed through a screw feeder 13 drivenby a motor 14 in direction A toward a die head 15. The molten tube 16 isextruded out of the die head 15, and can be optionally then fed to acorrugator 17 of the type as described above.

During manufacture, the molten tube 16 is passed between a series ofrotating moulds/blocks on the corrugator after exiting the extruder diehead 15 and is formed into a corrugated tube such as that illustrated inFIGS. 1, 7 and 8 for example.

The molten tube is formed by vacuum applied to the outside of the tubevia slots and channels through the blocks and/or pressure appliedinternally to the tube via an air channel through the centre of theextruder die core pin. If internal pressure is applied, a speciallyshaped long internal rod extending from the die core pin and fittingclosely with the inside of the corrugations may be required to preventair pressure escaping endways along the tube.

The tube 1 has a wall 3 that is preferably between approximately 0.3-1mm thick for a breathing tube of typical dimensions (i.e. betweenapproximately 10 mm and 30 mm diameter for neonatal and adultapplications respectively and approximately 1-2 meters in length).

Such a component according to this invention may also include includes aplain cuff region for connection to an end connector fitting.

Similarly, the end connector fitting of the present tube is preferablyof a standard type (moulded plastic) according to the intended use ofthe medical tubing and may preferably be permanently fixed and/or airtight by friction fit, adhesive bonding, over moulding, or by thermal orultrasonic welding etc. For example, the end connector may incorporatean internal medical taper.

One advantage of the preferred type of component or tube manufacturedescribed above with reference to FIG. 5 is that some of the mouldblocks B can include end cuff features that are formed at the same timeas the tubular component 1. Shown is a molten extruded tube 16 exitingthe die 15 of an extruder before passing into a corrugator 17. Onexiting the corrugator 17, a heater wire 6 is wound about the exteriorof the formed tubular component.

Manufacture speeds can be significantly increased by the reduction incomplexity and elimination of secondary manufacturing processes. Whilethis method is an improvement over separate cuff forming processes, adisadvantage of the prior art plain cuff is that the corrugator mustslow down to allow the wall thickness of the tube in this area toincrease (the extruder continues at the same speed).

The cuff thickness is increased to achieve added hoop strength andsealing properties with the cuff adaptor fitting.

Further, the heat of the molten polymer in this thicker region isdifficult to remove during the limited contact time with the corrugatorblocks and this can become an important limiting factor on the maximumrunning speed of the tube production line.

Condensate Accumulation Test—Performance Results

Test Method

The test circuit is laid horizontally inside a wind or convectiontunnel. Air flow inside the tunnel is set to about 0.5 m/s and the roomambient temperature is maintained at about 18° C. which is at thelower-end recommended use temperature for the humidifier. The tube isconnected to a humidification chamber that delivers moisture-saturated(i.e. >95% RH) air at 37° C.

Condensate is allowed to accumulate inside the tube and the weightgained by the tube in 16 hours is recorded as the accumulatedcondensate.

Condensate Test Experimental Results

TABLE 2 Condensate accumulation in breathing tube samples with differentadditive concentrations Reduction Condensate versus Accumulation currentin 16 hours product Sample Description (grams) (%) Current product127.18 — Linear Low-density Polyethylene (LLDPE) Linear Low-densityPolyethylene (LLDPE) 115.98 9 With 5% MLDNA-418 Surface ModificationAgent Linear Low-density Polyethylene (LLDPE) 105.34 17 With 10%MLDNA-418 Surface Modification Agent Linear Low-density Polyethylene(LLDPE) 118.11 7 With 1.0% CF20E Foaming Agent Linear Low-densityPolyethylene (LLDPE) 114.93 10 With 1.2% CF20E Foaming Agent LinearLow-density Polyethylene (LLDPE) 90.1 29 With 5% MLDNA-418 SurfaceModification Agent and 1.0% CF20E Foaming Agent Linear Low-densityPolyethylene (LLDPE) 83.16 35 With 5% MLDNA-418 Surface ModificationAgent and 1.2% CF20E Foaming Agent

Trends indicate that increasing surface modification agent contentincreases the impact of surface modification in condensate accumulationinside the tube. Results indicate that the benefit from foaming andsurface modification in reducing condensate is more than a linearaccumulation. It appears there are synergistic benefits from thecombination of foaming agent with a surface modification agent. Foamingagents produce air bubbles inside the tube during extrusion. Air has avery low thermal conductivity which causes a significant increase in thethermal insulation property of the tube.

From these results, it is apparent that small variations in thecomposition of the mix will have a significant impact to performance.

Visual Detection Test Method

Six (6) polyethylene breathing tube samples (corrugated, 22 mm diameterand 1.5 meter long) having MHYNA-CF20E foaming agent concentrations of0%, 1%, 1.2%, 1.5% and 1.8%, and 2.0% were assembled using standardbreathing circuit heater wires and connectors. A precision syringe wasused to inject 100 mL of clean deionized water in each of the tubes. Airwas allowed to pass through the test breathing tubes from a portableventilator.

The tubes with 0% (current state-of-the-art) and 2% MHYNA-CF20E (foamingagent master batch) were used as references to represent the extremeends of the transparency range to be evaluated, where for example, 0%having an acceptable water detectability (Reference A) and 2%MHYNA-CF20E having no water detectability at all (Reference B).

Ten (10) volunteer participants with varying age, ethnicity and genderwere asked to conduct a visual inspection of the tubes and evaluate theease with which they detected water inside the tube compared to thereference tubes in a scale of 1 to 5, as per the following guideline:

-   -   Water detectability is as good as in Reference A    -   Water is detectable but not as good as in Reference A    -   Water is reasonably detectable    -   Water is barely detectable but not as bad as Reference B    -   Water is as undetectable as in Reference B

Nine (9) out of ten (10) participants rated the tube with 1.2%MHYNA-CF20E as having reasonable water detectability with an averagescore of 3. On the other hand, the tube with 1% MHYNA-CF20E scored anaverage of 2. 10 out of 10 participants considered the tube as havingreasonable or better water detectability than the rest of the testsamples except Reference A. Results of the study showed that the 1.5%and 1.8% MHYNA-CF20E (greater than 10% foam/void fraction) haveunacceptable amount of foaming with 10 out of 10 indicating that the twotubes have very poor water detectability.

Further Performance Results

Table 3 sets out comparative data between reference samples of 100%LLDPE corrugate tubes (see reference samples 1, 2, 3) against corrugatedtubes of similar dimensions formed with a polymer material of LLDPE plusother materials. Reference sample 1 is the current state-of-the arthaving a 100% LLDPE corrugate tube and an internal coiled heater.Reference sample 2 is a 100% LLDPE tube with an internal coiled heaterand outer sheath of polyethylene. Reference sample 3 has a 100% LLDPEtube with an external filament heater and outer polyethylene sheath.

As shown, the various comparative corrugate tube forms comprises LLDPEas a polymers material plus a chemical foaming agent (examples 1, 2, 3),LLDPE plus a chemical surface modification agent (examples 4, 5, 6, 7),and LLDPE plus a combination of a chemical foaming agent and a chemicalsurface modification agent (examples 9, 10, 11, 12).

The examples exemplify the performance of the various tubes in respectof their condensate accumulation test results (test procedure being thesame as the data obtained in Table 2). Notably, the results for examples9-12 provide significant improvement over the reference samples in termsof reduction in accumulated condensation.

The examples also exemplify the surface modification achieved byincluding a chemical surface modification agent within the extrudate.Notably, the surface property contact angle (for water) was altered fromabout 97° in the reference samples to about 33° in the examples using asurface modification agent.

Further, there are unexpected improvements in the condensateaccumulation test results for examples 9-12. The foaming of the wall andalteration of surface properties of the wall surface provide forimproved condensate accumulation results over the reference samples.Those improvements are not a linearly cumulative of the benefits thatappear provided by either foaming or surface modification on their own.Such non-linear accumulation of performance indicates the synergisticbenefits of such combination.

It is believed the particular improvements are resultant from thecombination of increased void fraction in the tube wall (i.e. about 5.5%to 7.5% void fraction) due to foaming (and therefore thermal resistanceto heat losses from warm gases passing through the tube), and possiblyenhanced re-evaporation rates of condensate or other liquid build-up inthe tube due to reduced surface property contact angle for liquid on thewall surface within the tube.

Addition of an outer sheath to an extruded 100% LLDPE tube reducedcondensate accumulation by 26.7%. Furthermore, external filament heatingof a 100% LLDPE tube reduced condensate accumulation by 53.1%.Externally heating a surface modified tube that has not been foamed didnot give any condensate reduction benefits. On the other hand,externally heating a foamed conduit (without surface modification) gaveabout a further 4.6% condensate reduction.

However, external filament heating of a foamed and surface-modifiedbreathing tube gave a 27.8% less condensate compared to a similarlyexternally heated 100% LLDPE tube. This further demonstrates thesynergistic benefit from the combination of foaming andsurface-modification in minimizing condensate accumulation inside ahumidified breathing circuit.

Surface modification Tube wall thermal Base material (X wt. Foamingagent (wt. agent (wt. % of total Void fraction of tube conductivity Tubeexamples % of extrudate) % of total extrudate) extrudate) Wall thickness(mm) (%) (W/m°K) Reference 100% (0%) (0%) Crest- 0 0.4 sample 1 LLDPE0.3 Trough- 0.6 Reference 100% (0%) (0%) Crest- 0 0.4 sample 2 LLDPE 0.3Trough- 0.6 Reference 100% (0%) (0%) Crest- 0 0.4 sample 3 LLDPE 0.3Trough- 0.6 Example 1 99.99% Calcium (0%) Crest- 5.5 0.3 LLDPE oxide 0.4(0.01%) Trough- 0.7 Example 2 99.988% Calcium (0%) Crest- 7.5 0.3 LLDPEoxide 0.5 (0.012%) Trough- 0.7 Example 3 99.988% Calcium (0%) Crest- 7.50.3 LLDPE oxide 0.5 (0.012%) Trough- 0.7 Example 4 99.5% (0%) GlycerolCrest- 0 0.3 LLDPE monostearate 0.3 (0.25%) Trough- 0.6 Example 5 99.0%(0%) Glycerol Crest- 0 0.3 LLDPE monostearate 0.3 (0.5%) Trough- 0.6Example 6 99.5% (0%) Glycerol Crest- 0 0.3 LLDPE monostearate 0.3(0.25%) Trough- 0.6 Example 7 99.5% (0%) Glycerol Crest- 0 0.3 LLDPEmonostearate 0.3 (0.25%) Trough- 0.6 Example 8 99.0% 0%) Glycerol Crest-0 0.3 LLDPE monostearate 0.3 (0.5%) Trough- 0.6 Example 9 99.49% CalciumGlycerol Crest- 5.5 0.3 LLDPE oxide monostearate 0.4 (0.01%) (0.25%)Trough- 0.7 Example 99.488% Calcium Glycerol Crest- 7.5 0.3 10 LLDPEoxide monostearate 0.5 (0.012%) (0.25%) Trough- 0.7 Example 99.49%Calcium Glycerol Crest- 5.5 0.3 11 LLDPE oxide monostearate 0.4 (0.01%)(0.25%) Trough- 0.7 Example 99.488% Calcium Glycerol Crest- 7.5 0.3 12LLDPE oxide monostearate 0.5 (0.012%) (0.25%) Trough- 0.7 Heater wireused Surface Improvement (yes/no, location e.g. Property AverageCondensate Improvement over over within tube, outside Outer ContactAngle accumulation over existing product, Improvement over referencetube, embedded in sheath used Tube examples (degrees) 16 hrs (grams)reference sample 1 reference sample 2 sample 3 wall of tube) (yes/no)Reference 97 127.18 NA NA NA Internal No sample 1 Coiled HeaterReference 97 93.17 26.7% NA NA Internal Yes sample 2 Coiled HeaterReference 97 59.59 53.1% 36.0% NA External Yes sample 3 Filament HeaterExample 1 97 118.11 7.1% −26.8% −98.2% Internal No Coiled Heater Example2 97 114.93 9.6% −23.4% −92.9% Internal No Coiled Heater Example 3 9756.85 55.3% 39.0% 4.6% External Yes Filament Heater Example 4 33 115.988.8% −24.5% −94.6 Internal No Coiled Heater Example 5 30 105.34 17.2%−13.1% −76.8% Internal No Coiled Heater Example 6 33 81.45 36.0% 12.6%−36.7% Internal Yes Coiled Heater Example 7 33 61.82 51.4% 33.6% −3.7%External Yes Filament Heater Example 8 33 61.43 51.7% 34.1% −3.1%External Yes Filament Heater Example 9 33 90.10 29.2% 3.3% −51.2%Internal No Coiled Heater Example 33 83.16 34.6% 10.7% −39.6% InternalNo 10 Coiled Heater Example 33 70.36 44.7% 24.5% −18.1% Internal Yes 11Coiled Heater Example 33 43.05 66.2% 53.8% 27.8% External Yes 12Filament HeaterComponent of an Insufflation System

Laparoscopic surgery, also called minimally invasive surgery (MIS), orkeyhole surgery, is a modern surgical technique in which operations inthe abdomen are performed through small incisions (usually 0.5-1.5 cm)as compared to larger incisions needed in traditional surgicalprocedures. Laparoscopic surgery includes operations within theabdominal or pelvic cavities.

In abdominal surgery, for example, the abdomen is usually insufflatedwith carbon dioxide gas to create a working and viewing space. The gasused is generally CO2 which is common to the human body and can beabsorbed by tissue and removed by the respiratory system. It is alsonon-flammable, which is important because electrosurgical devices arecommonly used in laparoscopic procedures. The use of these devices tendsto create surgical smoke in the working space due to burning of tissue.Smoke evacuation systems which use a discharge arm or limb are commonlyused to remove the smoke from the surgical site, so that a surgeon cansee what he or she is doing, and so that this potentially harmfulmaterial does not remain within the body cavity post-surgery.

A typical smoke evacuation system generally includes a trocar and acannula at the end to aid insertion into the operative site. The smokeexits the insufflated abdominal area through the discharge limb. Thedischarge limb may be attached to the end of a laparoscopic instrumentso as to provide evacuation close to the site where electrocautery takesplace. Usually, the gases and smoke from the body cavity are filteredthrough a filter to remove particulate matter before they are vented toatmosphere.

It has been common practice in laparoscopic surgery to use dry gases.However, it is also desirable for the CO2 or other insufflation gas tobe humidified before they are passed into the abdominal cavity. This canhelp prevent ‘drying out’ of the patient's internal organs, and candecrease the amount of time needed for recovery from surgery.

FIG. 4 shows a typical insufflation system 200 such as might be usedwith the present invention. The insufflation system 200 includes aninsufflator 201 that produces a stream of humidified insufflation gasesat a pressure above atmospheric for delivery into the patient'sabdominal or peritoneal cavity. The insufflation system 200 includes aheater base 204 and humidifier chamber 203, with the chamber 203 in usein contact with the heater base 204 so that the heater base providesheat to the chamber. The insufflation gases are passed through thechamber 203 so that they become humidified to an appropriate level ofmoisture. The system includes a delivery conduit that connects betweenthe humidification chamber 203 and the peritoneal cavity or surgicalsite. The conduit has a first end and second end, the first end beingconnected to the outlet of the humidification chamber 203 and receivinghumidified gases from the chamber 203. The second end of the conduit isplaced in the surgical site or peritoneal cavity and humidifiedinsufflation gases travel from the chamber 203, through the conduit andinto the surgical site to insufflate and expand the surgical site orperitoneal cavity. The conduit can be formed of the tabular component 1according to this invention and the benefits thereof provided for such asurgical application. The system also includes a controller (not shown)that regulates the amount of humidity supplied to the gases bycontrolling the power supplied to the heater base 204.

The smoke evacuation system 202 comprises a discharge or exhaust limb205, a discharge assembly 207 and a filter 206. The discharge limb 205connects between the filter 206 and the discharge assembly 207, which inuse is located in or adjacent to the operative site. The discharge limb205 is a self-supporting conduit or tube (the conduit is capable ofsupporting its own weight without collapsing) with two open ends: anoperative site end and an outlet end is made of a breathable foamedmaterial as described in this specification.

When saturated gases pass out of the abdominal cavity, they contact thecooler walls of the discharge limb, which is normally around one metrein length or thereabouts and moisture in the gases tends to condenseonto the walls of the discharge limb or exhaust conduit. Water vapourcan also condense on the filter, which can saturate the filter and causeit to become blocked. This potentially causes an increase in backpressure and hinders the ability of the system to clear smoke.

The present medical tubing as described above with reference tobreathing tubes is also suitable for application in the delivery limb ofa surgical humidification system. In particular, the medical tubing ofthe present invention is appropriate for use in the evacuation orexhaust limb of a smoke evacuation system. The performance benefits ofthe tubing are a result of the improved rainout performance (i.e. lesscondensation forming) of the tubes of the present invention.

Other Applications

It is anticipated that the present invention will find other medicalapplications to which it is particularly suited. For example,applications where consistent heating or maintenance of heating oftubing conveying a humid gas in order to reduce the formation ofcondensation could benefit from the low cost and efficient heating ofthe present invention.

The foregoing description of the invention includes preferred formsthereof. Modifications may be made thereto without departing from thescope of the invention

To those skilled in the art to which the invention relates, many changesin construction and widely differing embodiments and applications of theinvention will suggest themselves without departing from the scope ofthe invention as defined in the appended preliminary claims. Thedisclosures and the descriptions herein are purely illustrative and arenot intended to be in any sense limiting.

The invention claimed is:
 1. A component forming a part of a breathingtube, the component comprising: a single extrudate defining a tubularbody, the tubular body having a foamed wall, wherein the foamed wall hasa void fraction of up to 10% that, in use, enables visual detection of aliquid within the tubular body; and the foamed wall being surfacemodified by chemical means to alter a surface tension of a wall surface.2. The component as claimed in claim 1, wherein the foamed wall issurface modified by increasing the surface tension of the wall surface.3. The component as claimed in claim 1, wherein the wall of the tubularbody comprises a corrugation profile, wherein the corrugation profilecomprises alternating outer crests and inner troughs.
 4. The componentas claimed in claim 3, wherein the tubular body is of a spiralcorrugation form.
 5. The component as claimed in claim 3, wherein theouter crests correspond to a location of maximum inner radius andmaximum outer radius of the tubular body, and the inner troughscorrespond to a location of minimum inner radius and minimum outerradius of the tubular body.
 6. The component as claimed in claim 1,wherein the tubular body has a substantially uniform wall thickness. 7.The component as claimed in claim 1, wherein the foamed wall has athickness of about 0.4 mm to about 0.8 mm.
 8. The component as claimedin claim 7, wherein the foamed wall has a thickness of about 0.6 mm. 9.The component as claimed in claim 1, wherein the foamed wall isthermally insulative of, at least, an interior of the tubular bodybounded by the foamed wall.
 10. The component as claimed in claim 9,wherein the foamed wall has a thermal conductivity of about 0.2 to 0.4W/m-° K.
 11. The component as claimed in claim 10, wherein the thermalconductivity of about 0.3 W/m-° K.
 12. The component as claimed in claim1, wherein the foamed wall is a single-piece of a foamed polymermaterial.
 13. The component as claimed in claim 1, wherein the foamedwall has a void fraction of about 5.5% to about 7.5%.
 14. The componentas claimed in claim 1, wherein the single extrudate comprises one ormore polymer(s).
 15. The component as claimed in claim 14, wherein thesingle extrudate comprises one or more of Linear Low DensityPolyethylene (LLDPE), Low Density Polyethylene (LDPE), Polypropylene(PP), Polyolefin Plastomer (POP), Ethylene Vinyl Acetate (EVA),plasticised Polyvinyl chloride (PVC), or blends of these materials. 16.The component as claimed in claim 1, wherein the single extrudatecomprises one or more chemical foaming agents.
 17. The component asclaimed in claim 16, wherein the one or more chemical foaming agentscomprises calcium oxide.
 18. The component as claimed in claim 17,wherein the single extrudate further comprises one or more surfacemodification agents.
 19. The component as claimed in claim 18, whereinthe one or more surface modification agents comprises glycerolmonostearate (GMS), ethoxylated amine, alkanesulphonate sodium salt, orlauric diethanolamide.
 20. The component as claimed in claim 1, whereinthe single extrudate comprises a polymer or polymers being at leastabout 98.4 weight percent (wt. %) of the total single extrudate.
 21. Thecomponent as claimed in claim 20, wherein the polymer or polymerscomprises at least about 99.49 wt. % or 99.4889 wt. % of the totalsingle extrudate.
 22. The component as claimed in claim 1, wherein thesingle extrudate comprises a chemical foaming agent as at least about0.005 weight percent (wt. %) of the total single extrudate.
 23. Thecomponent as claimed in claim 22, wherein the chemical foaming agentcomprises about 0.01 wt. % to 0.012 wt. % of the total single extrudate.24. The component as claimed in claim 1, wherein the single extrudatecomprises a surface modification agent as at least about 0.05 weightpercent (wt. %) of the total single extrudate.
 25. The component asclaimed in claim 24, wherein the surface modification agent comprisesabout 0.25 wt. % to 0.5 wt. % of the total single extrudate.
 26. Thecomponent as claimed in claim 1, wherein the tubular body enablessurface property contact angles of less than about 45 degrees (°). 27.The component as claimed in claim 1, wherein the single extrudate ismade from one or more of Linear Low Density Polyethylene (LLDPE), LowDensity Polyethylene (LDPE), Polypropylene (PP), Polyolefin Plastomer(POP), Ethylene Vinyl Acetate (EVA), plasticised Polyvinyl chloride(PVC), or blends of these materials.